Sunnen Introduces Two-Stage Honing Efficiency

March 29, 2011

Sunnen's new HTG series tube hones are designed as oil field workhorses with high-volume throughput and increased part capacity. The standard HTG-10000 is capable of handling standard part lengths up to 30 feet (9.14 m) and weights up to 17,600 lbs. (8000 kg). The HTG's ID range is 2 to 24 inches (50.8 to 609.6 mm), double that of previous generation machines, with an OD capacity of 26 inches (660.4 mm) standard, and up to 48 inches (1219.2 mm) as an option. The machine is suitable for instrument piping and down hole equipment applications, such as pumps/motors and hangers, and large hydraulic cylinders like those found on offshore oil platform stabilizers. A new proportional load control hydraulic system enables maximum utilization of hydraulic power, delivering power where needed during operation for maximum efficiency. The system can deliver up to 40 hp (29.83 kW) to the spindle and up to 18 hp (13.42 kW) to the tool stroking system, for metal removal rates of 200+ in3/hr (3500 cm3/hr) using superabrasives in steel as needed.

For increased speed and accuracy, the HTG uses a new precision hydraulic feed system that combines the force of hydraulics with the finesse of a sophisticated control. This includes servo position control of the feed system actuator, electronic pressure control, closed loop feedback and ability to operate both standard tooling as well as two-stage tooling. The machine features a 100-foot/min (30.48 m/min) maximum stroke velocity, 0-300 rpm spindle, and a tool feed force of up to 2500 lbs. (11,200 N). The new servo system on the feed axis provides increased accuracy, as well as improved maintenance, service and setups with no tuning required.

Another upgrade is a next-generation two-stage hone head capable of roughing and finishing without changing abrasives. The two-stage hone head is available with conventional abrasives or superabrasives. The U.S.-made HTG is available in two standard model sizes - the HTG-4000 with 4-meter (13.12 ft) stroke length and the 10-meter (32.81 ft) stroke HTG-10000. Built-to-order machine sizes include 6-, 8-, 12-, 14- meter stroke lengths, and custom-length designs can be quoted.

To save floor space, the HTG's electrical panel is mounted with the hydraulic power unit. The power unit is designed for ease of maintenance with accessible components, an easy-to-clean tank, cleanable air filters on the oil heat exchanger, and oil temperature/level indicators on the machine and on the control. A new work base has an improved design sloped to the center of the machine for removal of honing "mud," and includes standard full-time coolant flush. This means operators spend less time shoveling out the base of the machine during high production runs.

The HTG features a new easy-to-use Siemens PLC touch-screen control system with zero shutoff, feed pressure control, cross hatch angle calculator and a joy stick to allow the operator to move the honing tool over the stroke length. The new control system features complex software to maximize process efficiency in the background while providing easy-to-use, intuitive touch-screen operation. The power of the hydraulic system is controlled with precision, enabling better control for tough parts such as blind bores and shoulders. A load meter enables detection of tight bore conditions and the bore profile is included on the display. Other features designed to increase productivity include feed system soft start, and integral load meter and recommended settings based on part dimensions and material. The standard chain vise fixture is taken to the next level with a new ease of movement on the machine rails for locating during setups, as well as improved ergonomics and adjustments.